Dry Release of Multi-Layer Thin Films from Webs
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Solution Overview
Problem
Current methods for removing multi-layer thin films from webs require hazardous solvents like acetone, necessitating costly and complex wet processes, and often involve additional release layers, which are not necessary.
Innovation Solution
A method involving coating a web with a multi-layer thin film and applying a mechanical force to release it, potentially using a water-soluble polyvinyl alcohol release layer with low adhesion to the web, allowing for a dry process without solvents and eliminating the need for a release layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wet process using acetone is used to dissolve the release layer, then the multi-layer thin film can be stripped from the web, but hazardous and flammable solvents are required and special process equipment is needed for stripping, rinsing, filtration, and drying
Solution Approach 1:
The patent extracts and eliminates the hazardous acetone solvent from the stripping process by replacing it with a dry mechanical process using pressure and temperature control to release the thin film directly from the web without dissolution
Solution Approach 2:
The patent replaces the chemical wet process with a mechanical dry process, using applied pressure and temperature control to achieve film release instead of chemical dissolution, thereby eliminating the need for special solvent handling equipment
2Ease of manufacture
If a release layer is used between the multi-layer structure and the web, then the thin film can be released, but additional materials and process complexity are required
Solution Approach 1:
The patent removes the release layer component entirely from the system by using the native low-adhesion properties of the web surface, eliminating the need for additional release layer materials and the complex wet stripping process associated with them
Solution Approach 2:
The patent enables the web surface to serve its own function as a release surface by utilizing its inherent low adhesion properties, eliminating the need for separate release layer materials and simplifying the overall process
3Ease of manufacture
If a sodium chloride release layer is evaporated prior to coating, then the thin film can be released, but additional processing steps and material costs are incurred
Solution Approach 1:
The patent extracts and eliminates the sodium chloride release layer and its evaporation process by using the web's native surface properties for film release, thereby removing unnecessary processing steps and improving production efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables a simpler, cost-effective dry process for releasing multi-layer thin films from webs, reducing material costs and environmental hazards by eliminating solvent use and simplifying the process.
Implementation Method 1
applying a mechanical force to release the multi-layer thin film from the web
Data Source
AI summary
A method of forming a thin film device includes coating a web with a multi-layer thin film; and applying a mechanical force to release the multi-layer thin film from the web. Additional methods of forming a thin film device are disclosed.